Rug and methods of manufacturing and packaging

ABSTRACT

A rug a methods of manufacturing and packaging the rug. The rug, once manufactured, can be folded one or more times from an unfolded configuration to a folded configuration such that the area thereof is substantially reduced. In example embodiments, the rug is packaged in the folded configuration. A bag, shrink wrap or other packaging is provided for retaining the folded rug.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/469,825 filed Mar. 10, 2017, the entirety of which is hereby incorporated herein by reference for all purposes.

TECHNICAL FIELD

The present invention relates generally to the field of floor coverings such as a rug, and more particularly to a rug that is deformable or foldable for packaging, and to methods and processes for the manufacture and packaging thereof.

BACKGROUND

Area rugs of larger sizes are commonly packaged by rolling the rug along its length or width to define a generally elongate cylindrical member. For example, typical area rugs of larger sizes have an upper surface defining one or more cut and/or looped piles of yarn and a bottom surface having a backing material. The backing material can include a primary backing that the yarn is tufted through and a bonding agent generally adheres the primary backing material to a secondary backing material. In most cases, the backing materials (if two are used) and/or the bonding agent causes to the bottom surface of the rug to be relatively stiff and rigid. And because of the relatively stiff and rigid bottom surface, folding or creasing the rug (vs. rolling) causes substantially permanent creases or fold lines to be defined in the rug.

As such, a drawback to larger area rugs is the inability to package the rug in a compact manner due to the damage caused by folding and/or forming one or more creases along the backing material. And by packaging the larger area rugs inefficiently and in a rolled-up manner, shipping the rugs to a retailer and displaying the rugs on the retail floor presents additional drawbacks and requires an excessive amount of shelf space to accommodate the rolled-up larger area rugs. Further improvements in the field are desirable, and it is to the provision of a rug and methods of manufacturing and packaging that the present invention is primarily directed.

SUMMARY

In example embodiments, the present invention provides a rug and methods of manufacturing and packaging the rug. In example embodiments, the rug is folded from an expanded configuration to a folded configuration, and then the rug is placed within a bag or wrapped with a material for packaging within a box. The packaged rug being much more compacted allows for placement on a shelf at a retail store.

In one aspect, the invention relates to a method of manufacturing and packaging a rug. The method includes providing a rug comprising first and second ends defining a length therebetween and first and second sides defining a width therebetween, the rug being in an unfolded configuration; folding the first end second ends along the length to define first and second folded sections; folding the first and second folded sections along the length to lie against each other; folding the folded first and second folded sections along the width such that the rug is in a folded configuration; and placing the folded rug within packaging.

In example embodiments, the packaging includes a bag having a zippered portion for opening or closing the bag, and a handle attached to the bag for carrying the folded rug. Optionally, the packaging includes one or more layers of shrink wrap material. In one example embodiment, the folded rug wrapped in shrink wrap is placed within a cardboard box.

In example embodiments, the length of the rug is about 5 feet and the width of the rug is about 3 feet. In example embodiments, the rug defines an area of about 15 square feet. In example embodiments, the rug has one or more piles of yarn extending from an upper surface thereof. In example embodiments, the piles of yarn can be cut, loop or a combination thereof. In example embodiments, the rug includes a polyurethane backing defined on a bottom surface of the rug. In example embodiments, the polyurethane backing is substantially resilient and elastic such that applying one or more folds to the rug does not cause the rug to retain any creases therein.

In another aspect, the invention relates to a method of packaging a rug including providing a rug, the rug being in an unfolded configuration; folding the rug such that the rug is in a folded configuration; and packaging the folded rug. In example embodiments, in the unfolded configuration the rug includes first and second ends defining a length therebetween and first and second sides defining a width therebetween.

In example embodiments, folding the rug to the folded configuration includes folding the first end second ends along the length to define first and second folded sections; folding the first and second folded sections along the length to lie against each other; and folding the folded first and second folded sections along the width such that the rug is in a folded configuration.

In example embodiments, the packaging includes a bag having a zippered portion for opening or closing the bag, and a handle attached to the bag for carrying the folded rug. Optionally, the packaging includes one or more layers of shrink wrap material. In example embodiments, the folded rug that is wrapped in shrink wrap is further placed within a cardboard box. In example embodiments, the length of the rug is about 5 feet and the width of the rug is about 3 feet.

In yet another aspect, the invention relates to a packaged rug for placement on a retail shelf including a rug and one or more layers of material containing the rug. In example embodiments the rug is in a folded configuration. In example embodiments, a purchase display can be provided on the one or more layers of material to include any branding, indicia, instructions or other textual or graphical information relating to the rug contained therein. In example embodiments, the one or more layers of material define a generally transparent bag for containing the folded rug therein. In example embodiments, the bag includes a zippered portion for opening or closing the bag, and a handle attached to the bag for carrying the folded rug. Optionally, the one or more layers of material define one or more layers of shrink wrap material and one or more cardboard layers.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a rug in an unfolded or expanded configuration according to an example embodiment of the present invention.

FIGS. 2-6 show a method of folding a rug from an unfolded or expanded configuration to a folded or compacted configuration according to an example embodiment of the present invention.

FIG. 7 shows the rug of FIG. 6 packaged in a bag according to an example embodiment of the present invention.

FIG. 8 shows the rug of FIG. 6 packaged in shrink wrap according to one example embodiment of the present invention.

FIG. 9 shows the shrink wrap packaged rug of FIG. 8 laying beside a rug packaged in a bag according to another example embodiment of the present invention.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

The present invention may be understood more readily by reference to the following detailed description of example embodiments taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this invention is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed invention. Any and all patents and other publications identified in this specification are incorporated by reference as though fully set forth herein.

Also, as used in the specification including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment.

With reference now to the drawing figures, wherein like reference numbers represent corresponding parts throughout the several views, FIG. 1 shows a rug 10 according to an example embodiment of the present invention. In example embodiments, the rug 10 comprises a top or upper surface 12 having one or more cut and/or looped piles of yarn. In alternate example embodiments, the upper surface can comprise a plurality of weaves, stitches, etc. formed from a desirable material(s) for example, to provide a walking surface when the rug 10 is placed with a bottom surface 14 in contact with the floor surface. According to the depicted embodiment, the rug 10 comprises a plurality of cut piles defined along the upper surface 12.

As depicted in FIG. 2 and according to example embodiments, one or more backing layers can be applied to the bottom surface 14 as desired. According to one example embodiment, the bottom surface 14 comprises a polyurethane backing 15. U.S. Pat. No. 7,638,008 and U.S. Pat. No. 8,910,588 disclose a polyurethane coating process and device for coating the backing of carpet, the entirety of which is incorporated by reference herein. In example embodiments, the polyurethane backing 15 is substantially resilient and elastic such that applying one or more folds to the rug 10 does not cause the rug 10 to retain any creases therein. For example, according to example embodiments, the rug 10 can preferably be folded and unfolded as desired, for example, wherein one or more of the folds do not cause permanent creases to be retained in the rug 10.

In example embodiments, the rug 10 extends along a length L1 between a first end 20 and a generally opposite second end 22, and first and second sides 30, 32 define a width W1 therebetween. In example embodiments, the length L1 is between about 5-12 feet and the width W1 is between about 3-12 feet. According to one example embodiment, the dimensions of the rug 10 are such that the length L1 is at least about 5 feet and the width W1 is at least about 3 feet. For example, in contrast to washable bathmats and small scatter rugs made with rubber non-skid backings. These rubber backed rugs are small in size (less than 15 square feet). The rug 10 of the presently claimed invention defines an area of at least about 15 square feet (e.g., 3 feet×5 feet or larger). According to one example embodiment, the rug 10 of the presently claimed invention is generally intended for lying atop a floor surface such as a bedroom, living room or other room or other support surface having an area suitable for accommodating the rug 10 having an area of at least about 15 square feet.

FIGS. 2-6 shows a method of folding the rug 10 to be packaged according to an example embodiment of the present invention. In example embodiments, the rug 10 is positioned with the bottom surface 14 facing upwards such that the upper surface 12 is contacting the floor surface (e.g., the rug 10 is laying upside down on a floor surface). As shown in FIGS. 2-3, the first end 20 is folded along the length L1 to define a first folded section 40 such that the first end 20 is generally aligned with an elongate axis X that extends generally perpendicular to the length L1. In example embodiments, the X axis is generally positioned at a midpoint of the rug 10, for example, such that the length L2 is about a half the length L1. In example embodiments, with the first end folded to define the first folded section 40, the rug 10 comprises a length L3. In example embodiments, the length L3 is about three quarters of the length L1.

As shown in FIGS. 3-4, the second end 22 is similarly folded along the length L1 to align with the X axis and define a second folded section 42. Thus, both of the ends 20, 22 are generally positioned to abut each other along the X axis. As shown, the carpet 10 comprises a length L4, for example, which is about one half of the length L1 or generally similar to the length L2. As depicted in FIGS. 4-5, the first and second folded sections 40, 42 are then folded together about the X axis to lie against each other. In example embodiments, the rug 10 comprises a length L5, for example, about one fourth of the length L1.

As shown in FIGS. 5-6, with the folded sections 40, 42 folded together and laying against each other, the rug 10 is then folded about an elongate axis Y that is generally perpendicular to the extension of the X axis, for example such that the rug 10 is folded along the width W1. As depicted in FIG. 6, the rug 10 is in a deformed, compacted or folded configuration and ready to be packaged. In example embodiments, the rug 10 in the folded configuration comprises a width W2 and the length L5. In example embodiments, the width W2 is about one half the width W1.

In alternate example embodiments, the rug 10 can preferably be folded in a variety of other ways such that the rug 10 is compacted or collapsed in such a manner to allow the folded to rug to be packaged within a bag or other packaging, for example, such that the packaged rug can be placed on a shelf in retail stores. In example embodiments, preferably a plurality of packaged rugs can be placed on one or more shelves at a retail store.

In example embodiments as depicted in FIG. 1, the rug 10 comprises a width W1 of about 3 feet and a length L1 of about 5 feet. Accordingly, L2 is about 2.5 feet, L3 is about 3.75 feet, L4 is about 2.5 feet, L5 is about 1.25 feet, and W2 is about 1.5 feet.

Thus, in the unfolded or expanded configuration the rug 10 occupies an area of about 15 square feet and in the folded configuration (see FIG. 6) the rug comprises an area of about 1.875 square feet. Accordingly, by folding the rug 10, the area thereof can be substantially reduced to provide efficient and economical packaging. In alternate example embodiments, the rug 10 can be configured to comprise a length L1 and a width W1 as desired, for example, such that the area of the unfolded rug is less than or greater than about 15 square feet.

FIG. 7 shows a packaged rug 100 comprising the folded rug 10 fitted within a bag 110. In example embodiments, the bag 110 is generally transparent such that the folded rug 10 is viewable from external the bag 110. According to one example embodiment, the transparent bag 110 is provided for packaging a rug 10 that is intended to be placed on a shelf in a retail store. In example embodiments, with the bag being transparent, the customer can easily determine the color(s) and/or pattern(s) of the rug 10. In example embodiments, the bag 110 comprises a closure or zipper 120 to provide or prevent access within the bag 110. According to some example embodiments, the bag 110 comprises a handle 130 for carrying the bag 110. In example embodiments, a purchase display or insert 140 can be provided to include any branding, indicia, instructions or other textual or graphical information. According to one example embodiment, one or more graphical illustrations are provided on the insert 140 for indicating the care instructions, for example, to indicate that the rug is washable in a washing machine, or for example, to indicate that the rug must be professionally cleaned, etc. Further optional, the insert 140 can include directions for unfolding the rug 10, or can include a SKU or bar code for integrating with a retailer's inventory system.

FIG. 8 shows a packaged rug 200 including the folded rug 10 as described above wrapped in a shrink wrap material 210. In example embodiments, in addition to wrapping the folded rug 10 shrink wrap material, the folded rug 10 can further be packaged within a cardboard box. As similarly described above, the bag can be transparent for easy viewing of the folded rug 10 therein. In another example embodiment, the shrink wrap material is at least partially translucent or at least configured such that one or more portions of the folded rug is viewable through the shrink wrap material. In a similar manner, the cardboard box comprising the folded rug 10 contained within the shrink wrap material 210 can be placed on a shelf in a retail store, and can for example comprise any branding, indicia or other textual or graphical information.

FIG. 9 shows a packaged rug 300 including the folded rug 10 as described above packaged in a bag 310 and comprising a handle assembly 330 including a pair of rope-like grasping handles 332. As similarly described above, the bag can be transparent for easy viewing of the folded rug 10 therein, and can comprise a purchase display or insert 340.

According to additional example embodiments, the rug 10 can preferably be folded in an automated manner, for example, such that once the rug is manufactured and ready for packaging, one or more automated machines generally sequentially operate to fold the rug from the expanded configuration to the compacted configuration. Furthermore, the manufactured and folded rug can be packaged in an automated manner, for example, wherein the folded rug is presented such that it is inserted within a zippered bag or wrapped with a material and inserted within a cardboard box or other desired packaging.

While the invention has been described with reference to example embodiments, it will be understood by those skilled in the art that a variety of modifications, additions and deletions are within the scope of the invention, as defined by the following claims. 

What is claimed is:
 1. A method of manufacturing and packaging a rug, the method comprising: providing a rug comprising first and second ends defining a length therebetween and first and second sides defining a width therebetween, the rug being in an unfolded configuration; folding the first end second ends along the length to define first and second folded sections; folding the first and second folded sections along the length to lie against each other; folding the folded first and second folded sections along the width such that the rug is in a folded configuration; and placing the folded rug within packaging.
 2. The method of claim 1, wherein the packaging comprises a bag comprising a zippered portion for opening or closing the bag, and a handle attached to the bag for carrying the folded rug.
 3. The method of claim 1, wherein the packaging comprises one or more layers of shrink wrap material.
 4. The method of claim 3, further comprising placing the folded rug wrapped in shrink wrap within a cardboard box.
 5. The method of claim 1, wherein the length of the rug is about 5 feet and the width of the rug is about 3 feet.
 6. The method of claim 1, wherein the rug comprises an area of about 15 square feet.
 7. The method of claim 1, wherein the rug comprises one or more piles of yarn extending from an upper surface thereof.
 8. The method of claim 7, wherein the piles of yarn can be cut, loop or a combination thereof.
 9. The method of claim 1, wherein the rug comprises a polyurethane backing defined on a bottom surface of the rug.
 10. The method of claim 9, wherein the polyurethane backing is substantially resilient and elastic such that applying one or more folds to the rug does not cause the rug to retain any creases therein.
 11. A method of packaging a rug comprising: providing a rug, the rug being in an unfolded configuration; folding the rug such that the rug is in a folded configuration; and packaging the folded rug.
 12. The method of claim 11, wherein in the unfolded configuration the rug comprises first and second ends defining a length therebetween and first and second sides defining a width therebetween.
 13. The method of claim 12, wherein folding the rug to the folded configuration comprises: folding the first end second ends along the length to define first and second folded sections; folding the first and second folded sections along the length to lie against each other; and folding the folded first and second folded sections along the width such that the rug is in a folded configuration.
 14. The method of claim 11, wherein the packaging comprises a bag comprising a zippered portion for opening or closing the bag, and a handle attached to the bag for carrying the folded rug.
 15. The method of claim 11, wherein the packaging comprises one or more layers of shrink wrap material.
 16. The method of claim 15, further comprising placing the folded rug wrapped in shrink wrap within a cardboard box.
 17. The method of claim 12, wherein the length of the rug is about 5 feet and the width of the rug is about 3 feet.
 18. A packaged rug for placement on a retail shelf comprising: a rug, the rug being in a folded configuration; and one or more layers of material containing the folded rug, wherein a purchase display can be provided on the one or more layers of material to include any branding, indicia, instructions or other textual or graphical information relating to the rug contained therein.
 19. The packaged rug of claim 18, wherein the one or more layers of material comprise a generally transparent bag for containing the folded rug therein, the bag comprising a zippered portion for opening or closing the bag, and a handle attached to the bag for carrying the folded rug.
 20. The packaged rug of claim 18, wherein the one or more layers of material comprise one or more layers of shrink wrap material and one or more cardboard layers. 